Painting of Concrete, Masonry and Plaster Surfaces - Code of Practice, Part 1: Operations and Workmanship

IS 2395 Part 1: Scope Overview

• Scope: Covers operations and workmanship for protective coatings on steel structures.
• Painting Schedules: Detailed in IS 2395 Part 2 (1994).
• Terminology: Uses definitions from related IS codes like IS 2212, IS 2572, IS 1597, IS 1661, IS 2402, IS 2394, IS 456, and IS 1303.
• Rounding Off: Final test or analysis values must be rounded per IS 2:1960, maintaining the same significant figures as specified.

Key Points:

This part does not include detailed formulas or tables but sets the framework for workmanship and operational standards. For formulas and detailed specs, refer to Part 2 or related IS codes.

flowchart LR
    A[IS 2395 Part 1: Operations & Workmanship] --> B[Painting Schedules in Part 2]
    A --> C[Terminology from IS Codes]
    A --> D[Rounding off per IS 2:1960]

IS 2395 Part 1 - Terminology Key Points

• Terminology Source: Definitions are primarily referenced from multiple IS codes:

  • IS 2212:1991 (Paints and varnishes - Terminology)
  • IS 2572:1963 (Paints and varnishes - Vocabulary)
  • IS 1597 (Part 1):1967 (Paints and varnishes - Vocabulary)
  • IS 1661:1972, IS 2402:1963, IS 2394:1984, IS 456:1978, IS 1303:1983

• Rounding Off Rules (IS 2:1960):

  • Final test or analysis values must be rounded off per IS 2:1960.
  • The number of significant digits in the rounded value must match that of the specified value.

• Painting Schedules: Covered separately in IS 2395 Part 2:1994.

Summary Table: Rounding Off (IS 2:1960)

Notes:

• No direct formulas or tables for terminology in IS 2395 Part 1.
• Refer to the above IS codes for detailed definitions.
• Always apply IS 2:1960 for numerical rounding compliance.

flowchart TD
    A[IS 2395 Part 1 Terminology] --> B[Definitions from IS 2212, IS 2572, IS 1597, etc.]
    A --> C[Rounding off per IS 2:1960]
    A --> D[Painting schedules in IS 2395 Part 2]

IS 2395 Part 1: Necessary Information and Planning for Painting on Plaster Surfaces

Key Points from Clause 4.1:

For efficient painting planning, provide detailed data on:

• Surface Type: Concrete, masonry, or plaster; include previous treatments.
• Usage Situation: Internal or external finish; exposure to weather/rain.
• New Plaster Details: Backing type, plaster undercoat and finish, completion dates per room, and lime additions in finishing coat.

Additional Specifications:

• Rounding Off Values: Follow IS 2:1960 for numerical rounding; maintain significant figures as per the standard.
• Schedules: Painting schedules are detailed in IS 2395 (Part 2):1994.
• Water Filler Definition (Clause 3.3): A washable distemper paste (size, whiting, fine plaster) compatible with solvent-based paints.

Summary Table for Planning Information

Planning Workflow (Mermaid Diagram)

flowchart TD
    A[Start: Painting Project] --> B[Collect Surface Data]
    B --> C{Surface Type?}
    C -->|Concrete/Masonry/Plaster| D[Record Previous Treatments]
    D --> E[Identify Usage Situation]
    E --> F{Internal or External?}
    F -->|External| G[Assess Weather Exposure]
    F -->|Internal| H[Proceed]
    G --> I[Note Exposure Level]
    H --> J[New Plaster?]
    J -->|Yes| K[Record Backing, Undercoat, Finish, Lime Addition]
    J -->|No| L[Proceed]
    K --> M[Schedule Painting as per IS 2395 Part 2]
    L --> M
    M --> N[Plan Execution]

This ensures proper preparation and compliance with IS 2395 Part 1 for painting on plaster surfaces.

IS 2395 Part 1: Characteristics of the Substrata and Treatment (Clause 5)

Key Points on Substrata Characteristics:

• Calcareous surfaces (lime, cement plasters) are strongly alkaline and retain moisture long after construction.
• Alkali attack on paint is common; distinguish from neutral surfaces like calcium sulphate plasters.
• Porous surfaces cause variable suction, surface imperfections, and biological growth (mould, moss, algae).
• Proper treatment is essential to ensure paint adhesion and durability.

Treatment Guidelines:

• Allow sufficient curing and drying time for plaster/concrete to reduce moisture.
• Identify substrate type and previous treatments (Clause 4.1):
  • Type of surface (concrete, masonry, plaster)
  • Exposure conditions (internal/external, weather)
  • Backing and plaster composition, lime content
• Use suitable primers/sealers to neutralize alkalinity and control suction.
• Remove biological growth before painting.

Typical Preparatory Steps (from IS 2395 and good practice):

Moisture and Alkalinity Consideration Formula (General):

[ \text{Moisture Content} = \frac{\text{Weight of water}}{\text{Dry weight of substrate}} \times 100% ] Painting is recommended only when moisture content is below a critical threshold (~5%).

flowchart TD
    A[Identify Substrate Type] --> B{Is surface calcareous?}
    B -- Yes --> C[Check alkalinity & moisture]
    C --> D[Allow curing & drying]
    D --> E[Clean & remove biological growth]
    E --> F[Apply primer/sealer]
    F --> G[Apply paint system]
    B -- No --> E

Summary:
IS 2395 Part 1 emphasizes understanding substrate alkalinity and moisture, thorough cleaning, and proper priming to ensure durable paint on calcareous plaster and concrete surfaces.

IS 2395 Part 1: Selection of Paints - Key Points

• Reference for Paint Selection:
  Paint types and their application schedules are detailed in IS 2395 (Part 2): 1994. Part 1 refers to this for specific paint system selection.

• Surface Preparation:

  • Lime plaster surfaces must be prepared as per Clause 7.1 before painting.
  • Proper surface preparation is critical for paint adhesion and durability.

• Paint Application:

  • Paint application methods and tools must comply with IS 1477 (Part 1 & 2): 1971.
  • The choice of paint system depends on the existing surface condition and the desired finish (Clause 9.1.4).

Typical Paint Selection Criteria (from IS 2395 Part 2):

General Notes:

• Follow surface preparation strictly to avoid peeling or blistering.
• Use compatible paint systems when repainting over existing finishes.
• Refer to IS 2395 Part 2 for detailed paint schedules and compatibility tables.

flowchart LR
  A[Surface Preparation] --> B{Surface Type}
  B --> C[Lime Plaster]
  B --> D[Concrete]
  B --> E[Metal]
  C --> F[Apply Lime Wash/Distemper]
  D --> G[Apply Cement Paint/Acrylic]
  E --> H[Apply Synthetic Enamel/Epoxy]

For detailed paint system selection, consult IS 2395 Part 2: 1994 and application methods in IS 1477.

IS 2395 Part 1: Preparation of Background (Clause 2.3 & 7)

• Background surface preparation refers to cleaning, smoothing, and treating surfaces before painting.
• Clause 2.3 refers to Clause 7 for details.

Key Points from Clause 7 (Preparation of Background)

• For Lime Plaster Surfaces (7.1):

  • Surfaces must be sound, dry, and free from dust, grease, and loose particles.
  • Any cracks or defects should be repaired before painting.
  • Lime plaster surfaces often require a lime wash or colour wash as a primer.

• Information for Planning (Clause 4.1):

  • Type of surface: concrete, masonry, or plaster.
  • Previous treatments, if any.
  • Usage: internal or external, exposure to weather.
  • Details of plaster work: backing, undercoat, finish, completion date.
  • Presence of lime in finishing coat.

Typical Preparation Steps:

Reference for Paint Selection:

• Paint types and schedules are in IS 2395 Part 2 (1994).

flowchart TD
    A[Surface Assessment] --> B[Cleaning]
    B --> C[Repair Defects]
    C --> D[Drying]
    D --> E[Priming (Lime wash for lime plaster)]
    E --> F[Painting]

Summary: Proper preparation ensures adhesion and durability of paint. Follow IS 2395 Part 1 Clause 7 and consult Part 2 for paint selection.

IS 2395 Part 1: Application of Paint Finish - Key Points

Surface Preparation & Painting (Clauses 2.5, 8.1)

• Surfaces must be prepared as per Clause 7 before painting.
• Paint application tools and methods must comply with IS 1477 (Part 1 & 2): 1971.
• Proper surface cleaning, drying, and priming are essential.

Paint System Selection (Clause 9.1.4)

• Paint system choice depends on:
  • Existing paint type.
  • New paint finish requirements.
• Refer to IS 2395 (Part 2): 1994 for detailed paint compatibility and system selection.

Planning Data Requirements (Clause 4.1)

• Provide detailed info on:
  • Surface type (concrete, masonry, plaster).
  • Previous treatments.
  • Internal or external exposure.
  • Weather exposure level.
  • Nature of plaster backing and undercoat.
  • Completion date of plaster work.
  • Lime addition in plaster finish.

Typical Paint Application Process (per IS 1477)

1. Surface Cleaning → 2. Surface Drying → 3. Priming → 4. Undercoat → 5. Finish Coat

Important Specifications:

flowchart LR
    A[Surface Preparation] --> B[Priming]
    B --> C[Undercoat Application]
    C --> D[Finish Coat Application]
    D --> E[Inspection & Touch-up]

Summary: Follow IS 1477 for painting methods, refer IS 2395 Part 2 for paint system selection, and ensure detailed surface and environmental data for efficient paint finish application.

IS 2395 Part 1: Maintenance and Repainting Key Points

• Surface Preparation (Clause 7.1.3.2):

  • Remove existing paint showing flaking, bleaching, or saponification by scraping and washing.
  • Allow surface to dry completely before repainting.

• Painting Application (Clause 8.1):

  • Apply paint after surface preparation per Clause 7.
  • Use painting tools and methods as per IS 1477 (Part 1 & 2): 1971, which detail suitable brushes, rollers, spray equipment, and application techniques for various paint types.

• Schedules for Painting:

  • Detailed in IS 2395 Part 2 (1994), covering frequency and types of paint for different environmental exposures.

Typical Maintenance Repainting Procedure Summary:

flowchart TD
    A[Inspect Surface] --> B{Is paint defective?}
    B -- Yes --> C[Scrape & Wash]
    C --> D[Dry Surface]
    D --> E[Apply Paint as per IS 1477]
    B -- No --> F[No action needed]

For detailed paint types and schedules, refer IS 2395 Part 2 (1994).

IS 2395 Part 1 – Colour Washing Key Points

1. Preparation of Colour Wash (Clause 1.1 & 1.3)

• Lime: Use fat lime per IS 712:1984.
• Slaking: Mix 1 kg unslaked lime with ~5 L water; stand 24 hours; strain through coarse cloth.
• Additives per m³ cream:
  • Gum: 4 kg (dissolved in hot water)
  • Sodium chloride: 1.3 kg per 10 kg lime (dissolved in hot water)
  • Mineral colours: Added after above, must be lime-resistant.

Alternatives:

• Gum substitute: 0.14 kg glue per 10 kg lime.
• Exterior wash: Mix quick lime with 1 part tallow (or linseed/castor oil) per 12-16 parts lime, slake with minimal water, stir, cool, dilute, strain, then add mineral colours.

2. Surface Preparation (Clause 1.2)

• New work: Brush off mortar droppings, foreign matter; wet surface before washing.
• Old work: Remove loose scales, fill holes/patches <50 cm² with matching mortar; wet surface before application.

3. Application (Clause 1.3)

• Use Moonj brushes.
• Apply minimum two coats.
• Brush strokes per coat:
  • Horizontally: right to left, then left to right.
  • Vertically: bottom up, then top down.
• Allow each coat to dry before next.
• Finish: Smooth, uniform, no cracking/peeling, colour wash should not rub off easily.

Summary Table: Colour Wash Mix Components

Key Specifications & Formulas for Cement Painting (IS 2395 Part 1)

Preparation of Cement Paint

• Mixing ratio:
  Equal volumes of cement paint powder and water are mixed to form a thick paste, then diluted to a brushable consistency.

Coverage

• Covering capacity:
  3.0 to 4.0 m² per kg of cement paint for two coats on plastered surfaces.

Surface Preparation

• New cement/concrete surfaces:

  • Allow surface to dry before painting.
  • Thoroughly brush to remove dirt and loose material.
  • Avoid acid or salt treatments (e.g., zinc sulphate) to prevent efflorescence.
  • For old surfaces with vegetation, use ammoniacal copper solution to kill growth, then brush off residues.
  • Repair cracks in V-shape and allow to dry before painting.

• Gypsum plaster surfaces:

  • Test surface alkalinity (IS E-1).
  • Apply primer if surface shows patchy suction or efflorescence.
  • For neutral surfaces, primer may be optional.

Summary Table

flowchart TD
    A[Surface] --> B{New or Old?}
    B -->|New| C[Brush & Dry]
    C --> D{Cracks?}
    D -->|Yes| E[Cut V-shape & Repair]
    D -->|No| F[Proceed to Paint]
    B -->|Old| G{Vegetation?}
    G -->|Yes| H[Apply Ammoniacal Copper Wash]
    H --> I[Brush off Dead Growth]
    G -->|No| I
    I --> F
    F --> J[Apply Cement Paint (1:1 mix)]
    J --> K[Two Coats, Coverage 3-

IS 2395 Part 1: Tests Relating to Fitness of Plaster for Painting (Annex E)

Key Tests & Specifications

1. Test for Alkalinity (E-1)

• Determines if plaster contains free alkali (lime), which can cause paint defects.
• Lime plasters improperly gauged may develop surface crazing.
• Lime content should be noted to assess risk of alkali attack on paint.

2. Plaster Characteristics Affecting Paint Fitness

3. Common Defects & Remedies

• Crazing: From lime plaster; reduce by proper gauging.
• Sweating: Gypsum plaster exposed to damp; avoid moisture sealing.
• Dry Out: Rapid drying causes friability; avoid rapid drying and premature heating.
• Cracks: Cut V-shaped, wet before filling with lime-retarded hemi-hydrate plaster.

Summary Table: Plaster Fitness for Painting

flowchart TD
    A[Plaster Surface] --> B{Type of Plaster}
    B --> C[Lime Plaster]
    B --> D[Gypsum Plaster]
    B --> E[Cement Plaster]

    C --> F[Check Alkalinity]
    F --> G[Proper Gauging to Reduce C

IS 2395 Part 1 references several key Indian Standards for definitions and related specifications:

Referenced Indian Standards:

• IS 2212:1991 — Code of practice for paint rollers and brushes
• IS 2572:1963 — Specification for ready mixed paints, distempers, and enamels
• IS 1597 (Part 1):1967 — Methods of sampling and test for paints, varnishes, and related products
• IS 1661:1972 — Specification for synthetic enamel paints
• IS 2402:1963 — Methods of test for paints, varnishes, and related products
• IS 2394:1984 — Code of practice for painting of ferrous metals in buildings
• IS 456:1978 — Code of practice for plain and reinforced concrete
• IS 1303:1983 — Specification for zinc dust

Important Notes:

• Rounding Off: Follow IS 2:1960 for rounding numerical test results to the same significant figures as specified.
• These standards ensure consistency in testing, application, and quality control of paints and finishes.

Summary Table of Key Standards:

For detailed formulas or test procedures, refer to the specific IS codes mentioned above.

IS 2395 Part 1 (1994) — Committee Composition

Committee: Painting, Varnishing and Allied Finishes Sectional Committee, CED 34

Key Points:

• The committee comprises experts from industry, research institutes, government departments, and academia.
• Members represent organizations like:
  • Cole Paints & Contracts Pvt Ltd
  • Central Building Research Institute (CSIR)
  • ICI India Ltd
  • The Nataraj Paints Pvt Ltd
  • Indian Plywood Industries Research & Training Institute
  • Indian Institute of Architects
  • Directorate General of Supplies & Disposals
  • Tata Engineering & Locomotive Co Ltd
  • Ministry of Defence
  • Central Public Works Department
  • Bureau of Indian Standards (BIS) (Ex-officio)
• Chairperson: Shri B. Shirazi (Cole Paints & Contracts Pvt Ltd, Bombay)

Summary Table of Committee Composition

This composition ensures a multi-disciplinary approach covering research, manufacturing, application, and regulatory perspectives for painting standards.

graph TD
    A[Chairman: Shri B. Shirazi] --> B[Industry Experts]
    A --> C[Research Institutes]
    A --> D[Government Departments]
    A --> E